DE102008061495A1 - Integrated control and monitoring system for production and quality assurance processes in production lines with processing stations and / or tools - Google Patents

Abstract

In a control and guidance system for manufacturing and quality assurance processes in production lines with multiple processing stations and / or tools for performing respective quality assurance or manufacturing operations, the processing stations or tools each have at least one sensor for acquiring readings of at least one measure of quality assurance or manufacturing operation on one Product, and a transmitter / receiver for transmitting in the quality assurance or manufacturing process detected measurements immediately after their capture at least in near real time via a communication link to an evaluation station and for receiving feedback from the evaluation station. The evaluation station has a data processor and a data memory, and the evaluation station is a documentation program component for structured documentation of measured values of at least one measured variable recorded in the quality assurance or production process, a classification and evaluation program component, immediately after receipt of the measured values via the Communication line at least in near real time to classify and evaluate them and to derive at least one process influencing or process notification measure depending on their classification and evaluation, and assigned a transmitter / receiver to at least in near real time over the communication link a message with the .. ,

Description

Here becomes a control and monitoring system for production and quality assurance processes in production lines with processing stations and / or tools described. A manufacturing process can be an assembly process, or a fuel filling process, as well as measuring and Inspection process, or the like. Be. The processing stations and / or tools are, for example, screw, adhesive, rivet or Clipsanlagen, or also measuring instruments for quality assurance like torque wrench, rotation angle measuring key, Distance measuring probes, pressure gauges, or devices for Measurement of other physical or electrical quantities. The control and monitoring system serves to control the processes in to control and / or regulate the production lines.

Background and state of the art

The Atlas Copco Tools Central Europe GmbH offers systems that B. a torque or rotation angle controlled shutdown, monitoring the Operation including cycle control against forgotten screws as well monitoring the connection itself allows. How far Tightening parameters are exceeded or fallen below show the information systems z. B. also on the impulse wrench. With the Tensor SL small screwdriver from Atlas Copco Tools Central Europe GmbH can be safety and functional critical connections donate documentable. Furthermore, cordless screwdrivers with a Bluetooth radio interface offered for quality assurance. Become radio Process signals such as i. O. and n. I. O., (N. i.O. = Not in order), (i.O. = in order) but also the measured torque and rotational angle values, the number of completed fittings and the screwing times directed to a process controller. The process control can be the executed glands and the conveyor belt release a production line, for example, for one measure.

in the Framework of industrial production in production lines with processing stations and / or tools are so already today by different Processes result data from production checks or quality control measures generated and merged into different databases. By the Variety of processes and data is an evaluation only with high Personnel expenses possible. Manufacturer, ie operator of Production lines, therefore, need to be holistic Assessment of the processes waive and are confined to usually on individual actions when deviations occur, the coincidentally or only recognized by the user of the product become.

A statistical process control (SPC) for full coverage a production line can not be carried out in practice since they are not economically viable with existing systems reasonable effort means. As a result, there is no nationwide coverage Evaluation of current processes of a production line. These Situation leads to that in the production reality In case of errors in the production process often no or only late Corrective action can be taken.

Currently are available quality control systems, as shown above, individual systems or isolated solutions, Process the process data or view test data and collect. However, collected information is in the problem case Manually retrieve, assess and reconcile by the user. This is not economically feasible, as currently available Quality control systems more staff for the continuous data evaluation would be necessary as for the production process.

in addition comes that gauges from different manufacturers because of lack of compatibility of the transmission protocols only very limited directly and promptly with each other To be able to exchange information. This also hinders one holistic consideration of the production process under quality aspects.

In the automotive industry as a leading industry is usually associated with three risk classes (after the VDI / VDE 2862 ): safety, function and customer-critical connections. Some vehicle manufacturers merely differentiate between bolted connections that are documented for reasons of product liability and those that are not documented.

For such critical screw is sufficient not only that all N. i. O. glands are discovered. Also, the cycle control, so counting the i. O. glands are not enough. All safety-critical bolting cases must be documented with their tightening torque and angle. In addition to complete documentation of the tightening values, feedback is also sent to the worker handling the screwdriving tool or the processing station for process assurance. These serve bulbs on the screwdriver. They indicate whether the screw connection was made within the setpoint values (= i.O.) or is faulty (= ni O.). The control stations of machining stations or screwdriving tools have integrated SPC software tools for statistical monitoring, process diagrams, tightening curves and tightening analysis for process monitoring. In a further process safety level, all screwdriving tools are embedded in manual workstations and at automatic assembly stations in the constant exchange of data with a superior production control and management system.

data exchange in manufacturing plants over networks it allows individual Capture bolting in an assembly line. To do this also screwdriving tools with own sensors and IP address (Internet Protocol address), then the possibility provide a data reconciliation from plant to plant. If, for example, Incorrect misplacing in a factory can be determined whether this is strictly the production line of this Work or parallel production in other plants. So possible causes, eg. B. a newly delivered Screwless or problematic tightening tool settings limited become.

So for example, in the production control system PLUS from Daimler so-called tensor screwdriving tools from Atlas Copco Tools Central Europe GmbH used in vehicle production. These screwing tools at manual workstations and automatic assembly stations are with a higher-level control and guidance system in the data exchange. The production control system is transmitted here the bolt-specific target data to the screwdrivers and receives after the screwing the appropriate feedback.

Underlying problem

On systems currently available to the market for recording and However, visualization of the process data does not offer any in everyday production usable possibility, all relevant processes of a Production line so timely and fully automated too consider, possibly intervene and a process owner to inform so that mistakes or trend deviations still during Recognized and disposed of with economically justifiable effort can be.

solution

proposed becomes a control and guidance system for manufacturing and quality assurance processes in production lines with several processing stations and / or Tools for performing respective quality assurance or manufacturing operations. The processing stations, tools or Test equipment each have at least one sensor for detection of measured values of at least one measured quantity of the Quality assurance or manufacturing operation on a product. A sender / receiver is used for transmission in the quality assurance or manufacturing process of recorded measurements immediately after their Capture at least in near real time over a communication link to an evaluation station and to receive feedback from the evaluation station. The evaluation station has a data processor and a data store. The evaluation station is a documentation program component, covered by the quality assurance or manufacturing process Measured measured values of at least one measured variable to document, a classification and evaluation program component, immediately after receiving the measured values via the Communication link, at least in near-real time this in the Evaluation station to classify and evaluate and dependent on of their classification and evaluation at least one process influencing or process notification action, and infer Transmitter / receiver assigned to at least in near-real time via the communication line a corresponding message with the respective derived process control or process notification action to the respective processing station or the respective tool and / or deliver a control station.

From The control and guidance system will be after automatic reprocessing the measurement data a variety of process information such. B. error information or staff tours and quality control information back to the respective measurement data acquisition system of all Processing stations and / or tools given the production line.

ever after visualization possibility at the processing stations and / or tools of the production line acts the measurement data acquisition system then as an employee management system.

The The consequence of this is that the measuring systems will only be small in the future Storage capacities and computer capacities need. Also accounts for software packages for measuring data preparation, visualization as well as for storage and statistical calculation. The measurement data acquisition systems can be made cheaper.

• – Gezieltere Betriebsmittelauswahl (Werkzeug, Messmittel) für die Produktionslinie;
• – Erhöhte Produkt-Qualität bei geringerem Mess-Aufwand;
• – Erhöhte Produkt-Ausbringungsrate durch weniger Nacharbeit;
• – Erhöhte Transparenz aller Fertigungsvorgänge; und
• – Steigerung der Produktivität, verringerte Produktionskosten.

Such a system also offers, among others, the following advantages:

• - More targeted equipment selection (tool, measuring equipment) for the production line;
• - Increased product quality with less measuring effort;
• - Increased product application rate through less reworking;
• - Increased transparency of all manufacturing processes; and
• - Increased productivity, reduced production costs.

The system allows the simplification of the Quality control of manufacturing processes. The recorded readings are recorded online, ie in real time (less than about 10-100 milliseconds) or in near real time (within about 0.1-10 seconds, usually about 1 second), processed and initiated appropriate reactions. Due to this short response time and based on the complete consideration of previously acquired measured values as well as current measured values, production can still be intervened at a time when the product in question is still in the production line. This reduces the costs. The system can perform automatic assessments and arrange actions to be taken online. All measures / actions can be automatically documented and generated in a reporting subsystem.

basics Aspects are the online control of all monitored Processes of the production line, the reduction of effort in quality measures, the immediate initiation of corrective actions, as well short-term reactions in the event of trend deviations. Farther is it possible to dynamise test sequences, i. H. the distance between two or more test measures related to faulty processes depending on to change the measured values from the current production (to extend when the process dominates and in the desired Tolerance band is stable, or shorten, z. For example the process moves out of the desired tolerance band). The consequence of this is also the reduction of inspection / maintenance costs by resource-related reaction. Finally, the system can targeted information in the field of quality control and maintenance as well as product quality put what the effort for the evaluation compared the manual evaluation reduced many times over.

The Classification and evaluation program component serves to the detected measured values of the at least one measured variable in relation to custom and for the respective processing stations or tools to set custom specific rules.

The Custom specific rules are from a given Class of rules selectable and changeable. For this purpose, one or more process parameters can be used in each of the rules be linked to a first process influencing factor. Farther In each of the rules, one or more process weighting factors can be used linked to a second process influencing factor. In addition, in each of the rules one or more Ranges of values in which one or more of the measured values are classified after their arrival in the evaluation station. Finally, in each of the rules one or more Process influencing or process notification measures be determined depending on each detected Be delivered.

The Classification and Evaluation Program component linked according to the specific rules, the measured quantities recorded with the first and / or second process influencing factors, and determines in which of the value ranges one or more recorded measured values order to be dependent on the range of values or a value range violation or range violation one or more related messages with each derived Process influencing or process notification measures to the respective processing station or the respective tool and / or deliver the processing station.

• – Sollwerte etwa in Form von Drehmoment, Drehwinkel, Länge, oder Füllstand,
• – Toleranzen der Sollwerte,
• – Prüfparameter etwa in Form von Drehmoment, Drehwinkel, Länge, Füllstand,
• – Materialkonstanten etwa in Form von Reibwert, Härte, Dimensionen, E-Modul,
• – Prüf-Häufigkeit, und/oder
• – Werkzeugtyp in Form von Art, Ausführungtyp, oder dessen Funktionsweise.

The process parameters may include constants, such as

• - nominal values in the form of torque, angle of rotation, length, or level,
• - tolerances of the nominal values,
• - test parameters in the form of torque, angle of rotation, length, level,
• - Material constants in the form of friction coefficient, hardness, dimensions, modulus of elasticity,
• - Testing frequency, and / or
• - Tool type in the form of type, design type, or its operation.

• – Risiko-Klassifizierung etwa in Form von Bedeutung der Fertigungsstelle,
• – Know-How-Daten, und/oder
• – Risiko-Potential in Form von Rest-Risiko.

The process weighting factors may include factors such as

• - risk classification, for example in the form of importance of the manufacturing site,
• - Know-how data, and / or
• - Risk potential in the form of residual risk.

The Ranges of values may include areas such as action areas, in which can lie measured variables, such as an in-order area, one or more message areas, one or several warning areas, an over-in-order area, a or several areas of expansion, destruction, and / or deformation, a sub-in-order range, one or more in the tolerance range above the setpoint lying areas, and / or one or more in the tolerance range below the setpoint lying areas.

• – eine oder mehrere Trendmeldungen, wonach der Fertigungsvorgang sich verändert aber noch in Ordnung ist;
• – eine oder mehrere Meldungen von sporadischen Ausreißern der Messwerte;
• – eine oder mehrere Meldungen zur Einzelkontrolle und/oder zur Nacharbeit am Produkt;
• – eine oder mehrere Meldungen zum Anpassen des Prüfintervall am Produkt oder an den Bearbeitungsstationen und/oder Werkzeugen;
• – Instandhaltung/Wartung/Austausch des Betriebsmittels veranlassen bevor n. i. O.-Produkte die Produktionslinie verlassen;
• – Umfassende Überprüfung der noch nicht verbauten Bauteile veranlassen;
• – Stopp der Produktionslinie;
• – Auslieferungsstopp der betroffenen Charge veranlassen;
• – Ein oder mehrere Ersatzteile für die Bearbeitungsstationen und/oder Werkzeuge oder das Produkt anliefern;

umfassen.The process notification and / or process control measures may

• One or more trend reports indicating that the manufacturing process is changing but still in order;
• - one or more messages of sporadic outliers of the measured values;
• - one or more messages for individual checking and / or reworking on the product;
• - one or more messages for adjusting the test interval on the product or on the processing stations and / or tools;
• - arrange for maintenance / replacement of the equipment before any products leave the production line;
• - arrange a comprehensive inspection of the components not yet installed;
• - stop the production line;
• - induce delivery stop of the affected batch;
• - supply one or more spare parts for the processing stations and / or tools or the product;

include.

• – eine Rückmeldung an die jeweilige Bearbeitungsstation oder das jeweilige Werkzeug;
• – eine elektronische Nachricht an eine Kontrollstation;
• – ein Abschaltsignal an die Produktionslinie; und/oder
• – Veränderungen der Regeln;

umfassen.The process influencing or process notification measures may also

• - A feedback to the respective processing station or the respective tool;
• - an electronic message to a control station;
• A shutdown signal to the production line; and or
• - changes in the rules;

include.

The Communication link between processing station or the tool and the evaluation station may be wireless and / or wired Be communication line.

After all the evaluation station can use a visualization program component for automatic display of measured quantities recorded in the assembly process is associated with such parameters with respect to one or more Assembly points indicated by the classification and evaluating program component as a criterion be recognized.

In order to The system also offers the possibility of processes online to visualize and directly do a quality control for to allow the whole process as long as the product is still did not leave the production line.

This System replaces a large part of the existing, on SPC based (island) quality monitoring systems through a quality control system with minimal dead time.

All integrated into the system processing stations and / or tools are equipped with a data acquisition system and online via wireless transmission systems (eg. Bluetooth, IRDA or WLAN) or via a direct cable connection (eg Ethernet, factory bus, fieldbus, or other network) respectively.

The Processing stations and / or tools with the measurement data acquisition systems are for example screw, adhesive, rivet or clip systems, or also measuring instruments for quality assurance such as torque wrenches, Screwdriver test stations, pressure gauges, or Devices for measuring other physical or electrical Sizes. Since the storage and processing of recorded measured values in the central evaluation station with data processor and datastore, the memory / processing resources on the side of the measuring data acquisition systems of the processing stations and / or tools to be minimal. In addition, you can also designed future data acquisition systems be that they have no administration or processing of measurement data locally on the meter. All measurement data will be immediately after taking the measured values (online) via a delivered above described communication path to the system.

Only during a possible offline operation (if for a short time no Possibility for online transmission of the measured values exists) is a sufficient intermediate buffering on the measured data acquisition system to ensure.

The Communication is - to close the control loop all manufacturing and quality assurance processes - always constructed bidirectionally.

In The illustrations are based on a screwing process and the associated quality assurance measures the control loop of the Control and monitoring system for production and quality assurance processes illustrated in production lines. Of course the process is also at other processes in a production line usable.

Brief description of the drawings

1 shows a schematic representation of a production line, in which the control and monitoring system for manufacturing and quality assurance processes is illustrated in production lines with processing stations and / or tools.

2 schematically shows a server of the evaluation station in which several computer software program components are executed.

3 shows a classification and evaluation program component as a flowchart.

4 shows the formation of the rules according to which measured values are to be classified and evaluated, as a flowchart at a glance.

5 shows the formation of the rules according to which measured values are to be classified and evaluated, as a flowchart in detail.

6 shows the individual classification ranges and limits within which recorded measured values can lie, as well as the resulting classification in a schematic example.

7 schematically shows the individual classification ranges and limits and correspondingly assigned decision

8th schematically illustrates how and which first and second process influencing factors are linked together with value ranges defined in rules, in which value ranges the measured values are arranged or categorized.

9 schematically illustrates which statistical process control rules are integrated into the rules of the present system.

Detailed description of the system

1 shows a production line 10 on the products 12 using tools 14 to be assembled. The production line 10 is equipped with a control and guidance system for manufacturing and quality assurance processes. For this purpose, the tools have measurement data acquisition systems with one sensor 16 for detecting torque measured values occurring during the screwdriving process on one of the products 12 , The recorded torque measured values are transmitted via a transmitter / receiver 22 on the tools immediately after their detection via a communication link 24 to an evaluation station 30 Posted. The evaluation station 30 is also a transmitter / receiver 32 assigned. This transmitter / receiver 32 for receiving feedback from the evaluation station. In addition, the evaluation station has 30 a data processor 30a and a data store 30b , The evaluation station 30 is configured as a server, which is optionally set up via other data connections not shown with other (possibly also hierarchically superordinate) computers of the production company for data communication.

The measured values come from different data sources / data sinks: A first data source / data sink is the tool mentioned above, eg. B. an electric screwdriver 14a ; a second data source / sink is, for example, a torque check key 14b for recording process quality; a third data source / data sink is a test device 14c for recording the machine capability. With the second data source / data sink for recording the process quality, the production steps of several production tools - in chronological order of the immediate production process - are controlled. The third data source / sink may be a machine capability tester that controls the function / precision of the tools, timed apart from the immediate manufacturing process. With regard to data acquisition / data transmission and communication with the evaluation station 30 behave the three data sources / data sinks 14a . 14b . 14c comparable. So you can both send and receive data, whereby the communication can be wireless or wired.

In the server of the evaluation station 30 several computer software program components are executed (see 2 ). A documentation program component is used to document the measured values recorded in the quality assurance or manufacturing process in a structured manner and to store them according to a defined structure. A classification and evaluation program component (see 3 ) serves to classify and evaluate these immediately after the reception of the measured values via the communication path, at least in near real time, and to derive at least one process influencing or process notification measure depending on their classification and evaluation. These computer software program components process and evaluate all measurement data. In addition, information is automatically created / triggered for the respective processing point in the quality assurance or manufacturing process.

The already mentioned a transmitter / receiver 32 serves to deliver in near real time over the communication link corresponding messages with the respective derived process influencing or process notification measure to the respective processing station or the respective tool and / or a control station.

A core area of the classification and evaluation program component is the specification of the rules, according to which the communication path in the evaluation station 30 to classify and evaluate received measured values in order to derive the process influencing or process notification measures depending on their classification and evaluation (see 4 ).

This is done as the first - preparatory - step (see 5 ) defines one or more specific functional rules in dialogue with the classification and evaluation program component for each manufacturing site, tool, or processing station of the production line. For this purpose, each of the rules - in generic form - is issued from a given class of rules selects and changes user-defined. These generic rules have one

"IF

<factor A> <Operator 1>

• <factor B> <Operator 2> ...
• <Factor N> <operator n>
• <Measured value m> <operator m> <value range a> <operator>
• <Measured value m + 1> <Operator m + 1> <Range of values a> <Operator> ...
• <Measured value m + b>

• THEN

• <Process influencing measure 1> <Operator 1>
• <Process notification measure 1> <Operator 2> ...
• <Process influencing measure U> <Operator U>
• <Process notification measure V> "

Structure. The factors A, B ... N are process parameters that are linked become. The measured values m ... m + b are the current and the b past measured values. The consideration of a number past measured values is used to record trends, which the process is subject to.

It However, it is also possible, a first and / or a second Process influencing factor from one or more process parameters or from one or more process weighting factors by their determine respective linking.

These first and / or second process influencing factors then together with one or more value ranges defined in rules be linked. The measured values are in these value ranges arranged after their arrival in the evaluation station or categorized.

This is in 8th exemplified. Here it is shown how the individual factors are determined and which process influencing measures are to be taken or which process notification measures are to be derived. Here, under the influencing factors category, process, and residual risk, a further weighting takes place by - for example, dialog-guided or combined from database queries to the individual factors in order to be linked to the respective process influencing factor.

It can be set in the rules also limits reaching, exceeding or falling below in the Rules / actions to be defined.

While of the production process links the classification and evaluation program component according to the specific Regulate the measured quantities with the first and / or second process influencing factors, and determines in which of the value ranges one or more recorded measured values are, depending on the area classification one or several corresponding messages with respective derived process influencing or process notification actions to the respective ones Processing station or the respective tool and / or the control station leave.

So The user will have information, warning or action limits with different names and meanings as basic rules established. These limits are for the generation of actions or information always linked to a stored function. The operator decides for each production site / tool / requirements in his operation, etc. how many border areas are to be set.

For all measured quantities used, the total value range is broken down into subareas (see 6 ). The size and spacing of the boundaries of the areas is decided by the operator.

In the rules, each area can be linked to a function. Like in the 6 As an example, areas are defined which have information or action character after being determined by the user. Each area can be assigned a decision. (See also 7 ).

By the rule definitions are the procedures to configure freely. Each decision can be made by frequency or temporal Occurrence be set as information or action.

Examples for this are:
IF n measured values (n> = <a) of the last m measured values above the p. Action limit (p = 1 ... x), AND n measured values are below the upper tolerance limit, THEN message to the person responsible for quality, that the process is moving outside the previously defined tolerances AND shortening the check interval, AND signal to tool.
IF n readings (n> = <a) of the last m readings are above the tolerance limit, OR n readings below the upper analysis limit, THEN alarm to Quality Managers that the process is outside of the specified tolerances AND initiate machine testing and process analysis, AND signal to tool.
IF a reading is above the analysis limit, THEN stop the process AND alert quality managers that there is damage to the tool or component AND initiate a machine check AND conduct a process check.

The System is based on the incoming measurement data from process plants and measurement data acquisition systems based on a defined source to automatically collect via a communication path. These Measurement data are processed immediately according to the logic described above (calculated). This automatically becomes a defined action statement generated, which possibly leads to an immediate process intervention.

To Desire of the user can also after a previously defined time interval a staggered calculation can be selected.

at existing systems for process evaluation or quality assurance Compared to the logic above, measurement data is transferred and visualized upon manual selection of the user. This one has As a result, corrective action is delayed and happen to be possible.

at the present system will be canceled after the establishment of the rules All manual program controls necessary for quality control and decisions.

in the Rule system are also statistical rules (for example, is a value outside the intervention limit .... etc.) integrated. The present system offers the automatic calculation and integration of statistical Rules and the derived automatic action messages.

The System generates action messages, which are then processed unconditionally if the process requires it. All actions will be automatic documented with acknowledgment function and release system in an archiving system traceable recorded.

Three Risk classes are distinguished: safety, functional and customer-critical connections. Another division into risk classes are (screw) connections, for reasons of product liability to be documented and those that are not documented.

The control process begins with the determination of the risk potential of a bolting point, which occupies the control process with different priorities and actions. The risk potential of the respective bolting point is evaluated on the basis of different factors. Some factors to consider and link to can be: Application of the VDI / VDE 2862 , Effects in case of failure of the screwing point, Used technology, Used process protection, Risk potential in the assembly process, design defects, component defects, etc.

in the Interaction with the other rules will depend on the importance of Assembly operation and the risk potential is an action message for process intervention created.

The recorded measurement data are transmitted immediately online and then classified into the predetermined areas. From the respective area becomes in connection with the risk potential one previously defined process control action initiated.

at Existing SPC systems will not do an evaluation by areas is carried out. Rather, the quality manager must make an interpretation of the process and then a possible Process control from his experience work out what a longtime Experience and a detailed knowledge of the respective process means.

The presented system provides an automatic rating. Depending on Risk classification, this evaluation is carried out after a single value assessment or a long-term look at past readings. The position of the measured values (individual and long-term values) in connection with the action levels then leads to information or Action messages. The following factors are considered, among others: Measured values, their position of the measured values in the respective classification ranges, Mean value of previous measured values, number of measured values, scatter the measured values, action limits, or action areas, action field meaning, Risk assessment, etc.

The Scattering of the process will take place over a defined period of time automatically calculated. The dispersion is related to the action areas or limits are calculated and linked to the risk potential generates an action message. The action message is then canceled. Among other things, the following factors are taken into account: measured values, Scatter, mean, action range limits, etc.

For trend assessment, statistical process control rules are integrated into the rules and regulations of the present system. See also 9 ,

Systematic deviations are subject to regularities. From the course of the measuring points in the total value range, these laws can be deduced. So speaks one of a "trend" when seven measurement points show an at least linear slope in the direction of a boundary. There may be a sharp increase in tool wear, which soon causes the limit to be exceeded.

A Law ("Pattern") is a non-random curve, z. B. the periodic "swinging" the mean line. It can be caused for example by temperature fluctuations which are larger in production or smaller parts.

Are located 7 readings above or below the mean value line, have become the process mean probably shifted. It is from a run ("Run") spoken. This run can be for example indicate that a cutting edge has suffered damage and the parts from now on made larger or smaller.

The Intervention limits are not the only signs of potential problems; the arrangement of the measuring points is also to be observed. Are more than 90% of the measured values recorded in the middle Third of the range between the intervention limits or less as 40% of the points in this third, is also expected that there is a systematic (not accidental) influence.

These laws flow into the definition of the areas or their limits. They also serve to define the rules. ( 9 )

With The statistical trend rules can be a behavior (trend) of the process detected in the tolerance range and possibly visualized. This Trend is calculated automatically and in conjunction with the action fields and risk classes are evaluated and there are action messages (instructions for process control). Among others, the following are Factors taken into account: measured values, slope, statistical Characteristics, static rules, dispersion etc.

Rule factors:

• Risk class (A, B, or C)
• Tool technology (cordless screwdriver, electric screwdriver, pneumatic screwdriver ...)
• Process testing (retracting torque check, etc.)
• Process protection (yes, no)

Observations:

• 2 or more measured values exceed or fall below one action limit

Possible Cause:

• Over-adjusted machine, different material batches, damaged machine or product

Measures to be taken:

• Replacing production tool, 100% of all produced Check parts since last sample

In Production plants today are usually fixed test routes (temporal and content specification for examinations) available. These are usually given statically Time frame completed.

in the In contrast, in the present system, test routes automatically calculated and dynamically generated. So are expenses for quality control at secured Reduced processes and significantly increased in unsecured processes.

The Set of rules for a dynamic test route is under the conditions of the process decided. The user determines in the configuration menu, when and under what rules audits are carried out should be.

Running the process within statistical rules i. O., then the Test procedure changed so that between two tests can pass a longer time interval. The user decides during the rule definition in the configuration menu, which interval extension is allowed.

ever longer the process within the i. O. limits expires, the longer the time intervals between two exams set. However, there is an input for an interval limit, at which must be checked and a message which initiates an examination of the process.

There It can be assumed that most of the used Processes are process-capable, ie they are within a defined Probability i. O., is through the dynamic rules a substantial reduction in the scope of testing and a noteworthy saving in testing effort without sacrificing quality respectively.

Processes that are not statistically i. O. are, contain errors in their course, which can currently be detected only with great effort and usually only after a long time by chance. These unrecognized risks work in a process for a very long time and generate very high costs. These uncertain processes are documented by the dynamic test plan with shortened time intervals between two tests and the adjusted sample sizes. That is, the test cycle is automatically shortened. In the configuration menu, the rules for the test procedure (and the rates after which the test interval is extended / shortened) are fixed in advance.

As examples:
IF 2 values are above a specified or automatically established warning limit within one week THEN a check of the process is initiated.
IF 5 values within one week are outside the warning limit, THEN the test cycle will be shortened by 50%. This means that a duplication of the test is made.
IF 2 values are above or below an intervention limit (action limit) within one week THEN a duplication of checks is immediately initiated AND measures are suggested by an integrated expert system, which call for an action to bring the process back into control.

This Expert system consists of a variety of routines, which are from the Quality managers permanently through detailed Inputs can be extended. All parking measures the quality issues are detected and automatically the user offered.

occurring Quality changes are in the present System fully automatically recorded and calculated. The regulation takes place within a very short period of time and works early in the emergence of a quality deviation. this leads to to the fact that the effective saving also applies here and the overall scope the process control is significantly reduced.

There All processes can be mapped in the system for the first time is an expense-oriented demand planning via inspection capacities dynamically possible. Thus, personnel capacities can for the future, taking into account the current Process be planned. Downtime is through the system considered. Also the test equipment capacity (needed Testing equipment) can be planned.

The System gives on reaching the warning / action limits by the detected Measured out specific error codes that provide measures for Fixing the problem z. B. Testing effort or maintenance interval (reduce / increase), repair or replace the tool initiate mean. Error messages can additionally also directly to the maintenance instance and / or the responsible quality manager via SMS or email forwarded for information / processing become.

By the quality assessment in the current process should make it possible become the inspection effort and the maintenance interval of the production tool dynamically adapt.

If the quality also statistically i. O. is, so both the Trend development, as well as the individual values of the measured values i. O., the system automatically checks the inspection effort or the maintenance interval reduce (expense-oriented maintenance / repair).

Vice versa is detected when detecting quality deviations (eg tool wear) automatically increased in the process of testing effort and initiated an action to correct the problem.

The present system generates repair requests with repair timing and exact name z. B. the bolting, specific error message, Trend description as well as the repair measure. becomes one timely and cost-effective troubleshooting by the responsible Responsible and guaranteed at any time. there is the requirement for repair or maintenance by the present System through the information from the quality status of Process (machine and process capability) of the design of the Tool (in relation to overall performance) and the mechanical load created on the tool. Introducing the necessary steps to repair the tool or replace it with an identical one Tool is necessarily, that means without more here Actions, for example by personnel, would be required. The repair personnel are controlled by an expert system in a comparable manner as specified in the test routes, the measures for the execution of the repair job serve the tool targeted and to repair with the repair order scheduled by the system. This expert system consists of the same routines as in the dynamic test routes, permanent from the repair staff can be extended with inputs. There is repair information to the staff responsible for the repair. This information (Quality results, error message, etc.) will be online in transfer the repair area.

By the possible automation of ordering spare parts (orders) in the case of a tool defect, the costly spare parts inventory (not required) spare parts are avoided.

A customer-specific documentation for "ensuring the process" with recording of the initiated steps from the creation of the problem to the renewed tool release takes place automatically after the repair process has been completed. This process can be time consuming and thus costly documentation by hand (possibly also faulty) of the "repair process" in shift and asset books accounts. Furthermore, a documentation of "the entire process" for archiving in the higher-level control system can be made.

The The presented system therefore influences the production process using data immediately prior to their evaluation / division and then back into the production process and its quality. This is an essential one Difference in relation to previous systems in which the data collected are incomplete, and others are already out of date when they are evaluated. How much influence on the current production process? based on the already "outdated" data makes sense or even possible, depends heavily from the individual circumstances.

today Although manufacturing systems provide feedback to a single Tool / machining system back. This may be the case lead to an immediate intervention in the production plant. As an example, here is a missing screw called by the Control is detected as missing and leads to a blocking of the production cycle. It can only directly from the tool / processing system taken into account become. The majority of all production processes are missing however, readings entirely. Further influencing factors (Component influences, eg setting behavior, variants of component batches, unmeasured physical quantities z. B. friction coefficients, defects in the tool / in the metrology) are not considered in the decision. In contrast, the present captures and considers System when deciding on a specific manufacturing site also measured values / measured variables of other production sites and considers the instantaneous metric in the context of the rules that link further and comprehensive factors with the measured value and influence production. In individual cases leads This means that a detected measured value in known systems a Production line does not stop. With the present system leads however by the connection of the measured values with the factors in the rules, a metric to correct an error in manufacturing and to avoid mistakes in the future.

QUOTES INCLUDE IN THE DESCRIPTION

This list The documents listed by the applicant have been automated generated and is solely for better information recorded by the reader. The list is not part of the German Patent or utility model application. The DPMA takes over no liability for any errors or omissions.

Cited non-patent literature

• - VDI / VDE 2862 [0007]
• - VDI / VDE 2862 [0069]

Claims (15)

Control and guidance system for manufacturing and quality assurance processes in production lines with multiple Processing stations and / or tools to run respective quality assurance or manufacturing operations, wherein the processing stations or tools each at least - one Sensor for detecting measured values of at least one measured variable quality assurance or manufacturing operation on one Product, and - a transmitter / receiver to Send out in the quality assurance or manufacturing process detected measured values immediately after their detection at least in Near real-time via a communication link to one Evaluation station and for receiving feedback from the evaluation station and wherein the evaluation station a data processor and a data memory, and the evaluation station - one Documentation Program component for use in quality assurance or manufacturing process recorded measured values of at least one measured variable to document, - a classification and evaluation program component, immediately after receiving the measured values via the Communication path at least in near-real time to classify them and evaluate and depending on their classification and Evaluation of at least one process influencing or process notification measure derive, and - assigned a transmitter / receiver are at least in near-real time over the communication link an appropriate message with the respective derived process influencing or process notification action to the respective workstation or deliver the respective tool and / or a control station. Control and guidance system for manufacturing and quality assurance processes according to claim 1, wherein the classification and evaluation program component that included Measured values of the at least one measured variable in relation to custom and for the respective processing stations or tools specific rules sets. Control and guidance system for manufacturing and quality assurance processes according to claim 2, wherein the custom rules from a given class of Rules are selectable and changeable. Control and guidance system for manufacturing and quality assurance processes after one of the preceding ones Claims, wherein in each of the rules one or more process parameters are linked to a first process influencing factor. Control and guidance system for manufacturing and quality assurance processes after one of the preceding ones Claims, wherein in each of the rules one or more process evaluation factors are linked to a second process influencing factor. Control and guidance system for manufacturing and quality assurance processes after one of the preceding ones Claims, wherein in each of the rules one or more value ranges are set in which one or more of the readings after their Arrivals are to be classified in the evaluation station. Control and guidance system for manufacturing and quality assurance processes after one of the preceding ones Claims, wherein in each of the rules one or more Process influencing or process notification measures which are determined depending on each To submit measured values of at least one measured variable are. Control and guidance system for manufacturing and quality assurance processes after one of the preceding ones Claims, wherein the classification and evaluation program component according to the specific rules with the measured variables linked to the first and / or second process influencing factors, and determines in which of the value ranges one or more detected Measurements are to be classified, depending on the area classification one or more related messages with each derived Process influencing or process notification measures to the respective processing station or the respective tool and / or leave the control station. Control and guidance system for manufacturing and quality assurance processes after one of the preceding ones Claims, wherein the process parameters comprise constants, as - nominal values in the form of torque, angle of rotation, Length or level, - Tolerances the setpoints, - Test parameters approximately in shape torque, angle of rotation, length, level, - Material constants in the form of coefficient of friction, hardness, dimensions, modulus of elasticity, - test frequency, and or Tool type in the form of type, type of execution, or its operation. Control and guidance system for manufacturing and quality assurance processes after one of the preceding ones Claims, wherein the process weighting factors include, like - Risk classification about in shape of importance of the manufacturing site, - know-how data, and or - Risk potential in the form of residual risk. Control and guidance system for manufacturing and quality assurance processes after one of the preceding ones Claims, wherein the ranges of values include ranges, such as Action areas in which measured variables can lie such as an in-order area, one or more message areas, one or more warning areas, an over-in-order area, one or more destructive, tensile, and / or deformation regions, a sub-in-order range, one or more in the tolerance range above the setpoint lying areas, and / or one or more in the tolerance range below the setpoint lying areas. Control and guidance system for manufacturing and quality assurance processes after one of the preceding ones Claims, wherein the process notification and / or Process influencing measures - one or several trend reports indicating that the manufacturing process is changing but still okay, - one or more messages sporadic outliers of the measured values, - one or several messages for individual inspection and / or rework on the product - one or more messages for customization the inspection interval at the product or at the processing stations and / or tools, - Maintenance / Maintenance / Replacement of the equipment before n. i. O. products the production line leave - Comprehensive review cause the not yet installed components - Stop the production line - Delivery stop of the affected Initiate batch - One or more spare parts for the processing stations and / or tools or the Deliver product include. Control and monitoring system for manufacturing processes according to one of the preceding claims, in which the process influencing or process notification actions - one Feedback to the respective processing station or respective tool, - an electronic message to a control station, A shutdown signal to the Production line, and / or - changes the rules include. Control and monitoring system for manufacturing processes according to one of the preceding claims, wherein the communication path between the processing station or the tool and the evaluation station a wireless and / or wired communication link is. Control and monitoring system for manufacturing processes according to claim 1, wherein the evaluation station is a visualization program component for automatic display of measured quantities recorded in the assembly process is associated with such parameters with respect to one or more Mounting points are displayed by the classification and Evaluating program component as a criterion be recognized.